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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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NASA NTRS1984

A report on the USL NASA/RECON project. Part 1: The development of a transportable, university level, IS and R educational program

A project is described which has as its goal the production of a set of system-independent, discipline-independent, transportable college level courses to educate science and engineering students in the use of large-scale information storage and retrieval systems. This project is being conducted with the cooperation and sponsorship of NASA by R and D teams at the University of Southwest Louisiana and Southern University. Chapter 1 is an introduction, providing an overview and a listing of the management phases. Chapter 2 furnishes general information regarding accomplishments in areas under development. Chapter 3 deals with the development of the course materials by presenting a series of diagrams and keys to depict the progress and interrelationships of various tasks and sub-tasks. Chapter 4 presents plans for activities to be conducted to complete and deliver course materials. The final chapter is a summary of project objectives, methods, plans, and accomplishments.

Dominick, Wayne D.↗
NASA NTRS1989

A logical model of cooperating rule-based systems

A model is developed to assist in the planning, specification, development, and verification of space information systems involving distributed rule-based systems. The model is based on an analysis of possible uses of rule-based systems in control centers. This analysis is summarized as a data-flow model for a hypothetical intelligent control center. From this data-flow model, the logical model of cooperating rule-based systems is extracted. This model consists of four layers of increasing capability: (1) communicating agents, (2) belief-sharing knowledge sources, (3) goal-sharing interest areas, and (4) task-sharing job roles.

Bailin, Sidney C.↗
NASA NTRS1992

Advanced transportation system study: Manned launch vehicle concepts for two way transportation system payloads to LEO. Work breakdown structure and work breakdown structure dictionary

The report describes the work breakdown structure (WBS) and its associated WBS dictionary for task area 1 of contract NAS8-39207, advanced transportation system studies (ATSS). This WBS format is consistent with the preliminary design level of detail employed by both task area 1 and task area 4 in the ATSS study and is intended to provide an estimating structure for parametric cost estimates.

Duffy, James B.↗
NASA NTRS2005

Experiments and Models for Polymeric Microsphere Foams

The current project was performed under the direction of Dr. Byron Pipes as its lead investigator from January 2001 to August 2004. With the permission of the NASA, the project was transferred to Dr. Thein Kyu as the principle investigator for the period of September 2004 - June 2005. There were two major thrust areas in the original proposal; (1) experimental characterization and kinematics of foam structure formation and (2) determination of the mechanical, physical, and thermal properties, although these thrust areas were further sub- divided into 7 tasks. The present project has been directed primarily to elucidate kinematics of micro-foam formation (tasks 1 and 3) and to characterize micro-foam structures, since the control of the micro-structure of these foams is of paramount importance in determining their physical, mechanical and thermal properties. The first thrust area was accomplished in a timely manner; however, the second thrust area of foam properties (tasks 2,4-7) has yet to be completed because the area of kinematics of foam structure formation turned out to be extremely complex and thus consumed more time than what have been anticipated. As will be reported in what follows, the present studies have greatly enhances the in-depth understanding of mechanisms and kinematics of the micro-foam formation from solid powders. However, in order to implement all objectives of the second thrust areas regarding investigations of mechanical, physical, and thermal properties and establishment of the correlation of structure - properties of the foams, the project needs additional time and resources. The technical highlights of the accomplishment are summarized as follows. The present study represents a first approach to understanding the complexities that act together in the powder foaming process to achieve the successful inflation of polyimide microstructures. This type of study is novel as no prior work had dissected the fundamentals that govern the inflation process in this type of systems. The systematic approach to each of the different phenomena (i.e. morphological, diffusive, kinetic and dynamic) brings into context each of them in a way that allows separate understanding and analysis. Of the different phenomena studied, probably the one that gives a higher level of control over the inflation process has been shown to be the morphological aspects of the precursor particles. It is a major contribution of the present work to isolate and identify this phenomenon and highlight the features that with careful control during the synthesis of the precursor material can lead to a highly optimized and specialized final product (neat foam or microstructure). Some of these accomplishments have been presented in various national meetings and some of which are either published in refereed journals or still in various stages of publications. One of the presentations was selected for "Best of ANTEC 2004" Online Presentation Series of the Society of Plastics Engineers (SPE) (September 2004)

Pipes, R. Byrona↗
NASA NTRS2009

Effect of Changing Weight and Mass on Human Performance in a Lunar Prototype Spacesuit

Physical effort, compensation, and controllability in a spacesuit can be affected by suit mass and gravity level. Because of limitations in certain reduced-gravity simulators and the finite selection of lunar prototype suits, it is difficult to ascertain how a change in suit mass affects suited human performance. One method of simulating a change in mass is to vary the total gravity-adjusted weight (TGAW), which is defined as the sum of the suit mass and subject mass, multiplied by the gravity level. PURPOSE: To determine if two methods of changing TGAW during parabolic flight - changing suit mass or gravity level - affect subjective ratings of suited human performance equally. METHODS: A custom weight support structure was connected to a lunar prototype spacesuit, allowing the addition of mass to the suit while maintaining a near-constant center of mass. In the varied-weight (VW) series, suit mass (120 kg) was constant at 0.1 G, 0.17 G, and 0.3 G, yielding TGAWs of 196, 333, and 588 N, assuming an 80-kg subject. In the varied-mass (VM) series, gravity level was constant at 0.17 G and suit mass was 89, 120, and 181 kg, yielding TGAWs of 282, 333, and 435 N. The 333 N condition was common to both series. Direct comparison was not possible due to limited adjustability of suit mass and limited options for parabolic profiles. Five astronaut subjects (80.3 11.8 kg) completed 4 different tasks (walk, bag pickup, lunge, and shoveling) in all conditions and provided ratings of perceived exertion (RPE) and the gravity compensation and performance scale (GCPS) upon completion of each task. RESULTS: Where VM and VW series overlapped, RPE and GCPS trendlines were similar. Mean RPE and GCPS at 333 N was 8.4 and 3.7. Mean RPE and GCPS for VM was 7.8 and 3.8 for 282 N and 9.8 and 4.1 for 435 N. Extrapolation of the VM trend to match VW TGAWs 196 and 588 N predicts an RPE of 6.5 and 12.3 and GCPS of 4.4 and 5.9, whereas the measured VW values for RPE were 8.1 and 9.8 and GCPS were 4.4 and 3.7. CONCLUSION: Modeling a change in suit mass by altering weight alone may be an adequate simulation through a limited range when looking at gross metrics of subjective suited human performance. Whether altering weight alone will be sufficient for more precise metrics of human performance, and across a wider range of activities, still needs further study.

Norcross, Jason R.↗
NASA NTRS2010

Effect of Changing Weight and Mass on Human Performance in a Lunar Prototype Spacesuit

Physical effort, compensation, and controllability in a spacesuit can be affected by suit mass and gravity level. Because of limitations in certain reduced-gravity simulators and the finite selection of lunar prototype suits, it is difficult to ascertain how a change in suit mass affects suited human performance. One method of simulating a change in mass is to vary the total gravity-adjusted weight (TGAW), which is defined as the sum of the suit mass and subject mass, multiplied by the gravity level. PURPOSE: To determine if two methods of changing TGAW during parabolic flight - changing suit mass or gravity level - affect subjective ratings of suited human performance equally.METHODS: A custom weight support structure was connected to a lunar prototype spacesuit, allowing the addition of mass to the suit while maintaining a near-constant center of mass. In the varied-weight (VW) series, suit mass (120 kg) was constant at 0.1-g, 0.17-g, and 0.3-g, yielding TGAWs of 196, 333, and 588 N, assuming an 80-kg subject. In the varied-mass (VM) series, gravity level was constant at 0.17-g and suit mass was 89, 120, and 181 kg, yielding TGAWs of 282, 333, and 435 N. The 333 N condition was common to both series. Direct comparison was not possible due to limited adjustability of suit mass and limited options for parabolic profiles. Five astronaut subjects (80.311.8 kg) completed 4 different tasks (walk, bag pickup, lunge, and shoveling) in all conditions and provided ratings of perceived exertion (RPE) and the gravity compensation and performance scale (GCPS) upon completion of each task. RESULTS: Where VM and VW series overlapped, RPE and GCPS trend lines were similar. Mean RPE and GCPS at 333 N was 8.4 and 3.7. Mean RPE and GCPS for VM was 7.8 and 3.8 for 282 N and 9.8 and 4.1 for 435 N. Extrapolation of the VM trend to match VW TGAWs 196 and 588 N predicts an RPE of 6.5 and 12.3 and GCPS of 4.4 and 5.9, whereas the measured VW values for RPE were 8.1 and 9.8 and GCPS were 4.4 and 3.7. CONCLUSION: Modeling a change in suit mass by altering weight alone may be an adequate simulation through a limited range when looking at gross metrics of subjective suited human performance. Whether altering weight alone will be sufficient for more precise metrics of human performance, and across a wider range of activities, still needs further study

Chappell, Steve↗
NASA NTRS2011

Status of 3D Ice Shape Measurement Effort

(1) Main goal of the Airframe Icing Technical Challenge is to achieve acceptance of experimental and computational icing simulation tools -SupercooledLarge Droplet Icing (SLD) conditions -3D airframe components including swept wings; (2) It is necessary to develop suitable means of recording and archiving fully 3D descriptions of experimental ice accretion geometry; (3) Past research has shown that commercial laser scanners have the potential to be adapted to this task; and (4) A research plan has been developed to implement and validate the use of this technology for experimental ice accretions.

Lee, Sam↗
NASA NTRS2015

On-Orbit Measurement of Next Generation Space Solar Cell Technology on the International Space Station

Measurement is essential for the evaluation of new photovoltaic (PV) technology for space solar cells. NASA Glenn Research Center (GRC) is in the process of measuring several solar cells in a supplemental experiment on NASA Goddard Space Flight Center's (GSFC) Robotic Refueling Mission's (RRM) Task Board 4 (TB4). Four industry and government partners have provided advanced PV devices for measurement and orbital environment testing. The experiment will be on-orbit for approximately 18 months. It is completely self-contained and will provide its own power and internal data storage. Several new cell technologies including four- junction (4J) Inverted Metamorphic Multijunction (IMM) cells will be evaluated and the results compared to ground-based measurements.

solar cell↗
NASA NTRS2016

NASA Glenn Research Center Solar Cell Experiment Onboard the International Space Station

Accurate air mass zero (AM0) measurement is essential for the evaluation of new photovoltaic (PV) technology for space solar cells. The NASA Glenn Research Center (GRC) has flown an experiment designed to measure the electrical performance of several solar cells onboard NASA Goddard Space Flight Center's (GSFC) Robotic Refueling Missions (RRM) Task Board 4 (TB4) on the exterior of the International Space Station (ISS). Four industry and government partners provided advanced PV devices for measurement and orbital environment testing. The experiment was positioned on the exterior of the station for approximately eight months, and was completely self-contained, providing its own power and internal data storage. Several new cell technologies including four-junction (4J) Inverted Metamorphic Multi-junction (IMM) cells were evaluated and the results will be compared to ground-based measurement methods.

Solar Cell Calibration Facility↗
NASA NTRS2016

Further Analyses of the NASA Glenn Research Center Solar Cell and Photovoltaic Materials Experiment Onboard the International Space Station

Accurate air mass zero (AM0) measurement is essential for the evaluation of new photovoltaic (PV) technology for space solar cells. The NASA Glenn Research Center (GRC) has flown an experiment designed to measure the electrical performance of several solar cells onboard NASA Goddard Space Flight Center's (GSFC) Robotic Refueling Mission's (RRM) Task Board 4 (TB4) on the exterior of the International Space Station (ISS). Four industry and government partners provided advanced PV devices for measurement and orbital environment testing. The experiment was positioned on the exterior of the station for approximately eight months, and was completely self-contained, providing its own power and internal data storage. Several new cell technologies including four-junction (4J) Inverted Metamorphic Multi-Junction (IMM) cells were evaluated and the results will be compared to ground-based measurement methods.

multi-junction↗
NASA NTRS2024

Interim Groundwater Monitoring Report, Revision 0, Fluid Servicing Road Area, Solid Waste Management Unit (SWMU)s 037 and 102, Kennedy Space Center, Florida

This Interim Groundwater Monitoring (IGWM) Report presents the findings from the IGWM events, completed between December 2022 and June 2023, at the Fluid Servicing Road Area (FSRA), Kennedy Space Center (KSC), Florida. KSC is located on the northern portion of Merritt Island, between the Indian and Banana Rivers in Brevard County, Florida. The IGWM program is implemented at sites where active remediation is not occurring. The IGWM events at the Propellants Support Building Area (PSBA; Solid Waste Management Unit [SWMU] 102) included the collection of eight groundwater monitoring well samples and 107 direct-push technology (DPT) samples. The DPT samples were collected for the Five-Year supplemental plume monitoring event. Additionally, 27 wells were sampled as part of the December 2022 IGWM event at the Former Drum Storage Area (FDSA), SWMU 037. This IGWM Report was prepared by HydroGeoLogic, Inc. (HGL) for the National Aeronautics and Space Administration (NASA) under Task Order 4 of Indefinite Delivery Indefinite Quantity Contract 80KSC019D0012/80KSC019F0090.

FDSA↗
DOE OSTI2024

Application of Banking Scoring and Rating for Coherent Risk Measures in Electricity Systems ABSCORES

This project developed a framework for asset and system risk management that can be incorporated into current electricity system operations to improve economic efficiency and establish an Electric Assets Risk Bureau. We leveraged scoring and ratings from banking and financial institutions alongside current optimization methods in dispatching power systems to help system operators and electricity markets schedule resources. This approach is based on the observation that there are major discrepancies between the power scheduled by a system operator and the actual power generated/consumed. These discrepancies—exacerbated by unplanned contingencies (e.g., natural disasters)—are caused by multiple factors, including the different financial, environmental and risk preferences of power producers, consumers, and aggregators. We developed a framework that counteracts two failures in electricity system operations: imperfect information and missing markets for products. The technical approach included five tasks. Tasks 1 and 2 supported the development of risk scores at the asset level with historical data collected for this project. Tasks 3, 4, and 5 incorporated scoring into decision-making at the system level. The proposed effort achieved PERFORM's Program Objectives because the proposed outputs and algorithms do not exist in the electricity industry and are an innovative approach to managing risk. Since the acknowledged need to better assess and act upon risk profiles for grid assets has not been met by the industry, this project will also impact ARPA-E's Mission Areas, including improving energy efficiency and giving the U.S. a technological lead in advanced energy technologies.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2021

Big Adaptive Rotor Phase I (Final Report)

The Big Adaptive Rotor (BAR) project was initiate by DOE in 2018 with the goal of identifying novel technologies that can enable large (>100m) blades for low specific power (SP) turbines. Five distinct tasks were completed to achieve this goal: 1. Assess trends, impacts, and value of low-SP turbines, 2. Wind turbine blade cost reduction roadmap study, 3. Research and Development (R&D) opportunity screening, 4. Detailed design and analysis, and 5. Low-cost carbon fiber. These tasks were completed by the national lab team consisting of Sandia National Laboratories (SNL), the National Renewable Energy Laboratory (NREL), and Lawrence Berkeley National Laboratory (LBNL). The objective of Task 1 was to assess the historical trends of low-SP of onshore deployments, and to assess the impact and value of low-SP turbines. Analysis under this task showed that there is significant value for low-SP turbines, especially in markets where there is a higher saturation of wind energy on the grid. This has to do with the fact that low-SP turbines have increased capacity factors, and can contribute more reliable energy to the grid, even in lower wind conditions. This bodes well as higher renewable scenarios are likely in the coming years. Task 2 was a detailed analysis on the logistical challenges of deploying very large (>100m) onshore blade. This work was completed by experts at DNV-GL. The report looked at various ways to get around the current transportation constraints which are estimated to be around 75m in length. The report concluded that there are viable solutions to this issue including: segmented blades (which the industry is already pursuing), lighter than air (LTA) transportation, on-site manufacturing, and controlled bending of blades on rail. The final option was recommended for further analysis and study by DOE and the national labs because keeping a single piece blade reduces manufacturing and operations and maintenance (O&M) costs. Task 3 focused on identifying novel concepts that are capable of enabling a cost effective 5MW 206m rotor for onshore deployment. The findings from the first two tasks were considered in the analysis, in that the concepts identified must be able to overcome the transportation logistics challenges. Around 20 concepts were identified and evaluated by experts within the industry. Additionally, science and engineering challenges were identified for each concept. Based on these evaluations six concepts were deemed the most impactful and were selected for further analysis in Task 4. The concepts were: highly flexible rail transportable blades, downwind rotors, distributed aerodynamic control (DAC) devices, inflatable blade, bi-wing blade, and 4/5 bladed rotors. Task 4 conducted detailed design, optimization, and analysis on the selected BAR concepts. A modeling gaps analysis was conducted, and modeling improvements were implemented that allowed for the study and design of the novel concepts. The BAR team established a set of baseline designs by which to compare the selected designs through a technoeconomic analysis. It was found that the highly flexible rail transportable blade, the downwind rotor, and the DAC devices have the most promise to deliver the BAR targets. A Phase II for BAR has been proposed to further mature these concepts and address the open science and engineering challenges identified in Task 3. Task 5 conducted research on optimized carbon fiber materials that were used throughout the BAR Phase I project. Overall, the BAR project has identified low-SP turbines as important to continued LCOE reductions for onshore turbines. Furthermore, the project has identified viable solutions to the technical and logistical challenges to realizing these goals. The most promising technologies that were identified in Phase I of the project will be further matured and de-risked in Phase II of the BAR project.

17 WIND ENERGY↗
DOE OSTI2026

Solutions to Droop and the Green Gap by Novel Carrier Injection

Long-wavelength (green, yellow, red) visible light-emitting diodes (LEDs) have historically been inefficient compared to blue light-emitters in the III-nitrides. This is due to many factors, including poor material quality due to the low growth temperatures required for high Incomposition InGaN quantum wells (QWs), and the polar nature of the III-nitride crystal structure. Spontaneous and piezoelectric polarization in the III-nitrides causes enhanced quantum-confined Stark effect (QCSE), which spatially separates electrons and holes and reduces radiative recombination (ie: light output) from the devices. Polarization in the crystal also induces additional potential barriers that electrons and holes must cross over before entering the QWs where they can recombine to emit light. Both of these polarization effects worsen as emission wavelength increases, making blue III-nitride LEDs are the most efficient and red III-nitride LEDs the least efficient. The focus of this project has been solving the latter polarization-related issue through the implementation of V-defects in long wavelength LEDs. V-defects are morphological defects which are commonly observed in c-plane III-nitrides. They are observed as hexagonal pyramid-shaped depressions on the c-plane surface, with six semipolar sidewalls. They typically form at the apex of threading dislocations (TDs) under conditions of kinetically-limited growth and low growth-temperature. They were initially thought to be detrimental to LED performance and much early work focused on eliminating them entirely from III-nitride devices. However, over the past decade work has emerged that indicate that they can improve LED performance by allowing electrons and holes to bypass the polarization-induced barriers present in the c-plane and directly enter the QWs of an LED. This is due to the semipolar nature of the V-defect sidewall: these sidewalls are thin and lack the polarization-induced barriers which prevent carriers easily moving between layers. V-defects have since been determined to be an efficient avenue by which to inject electrons and holes into the c-plane QWs where they can recombine to emit light. Throughout this project we have explored lateral injection through a variety of methods: simulation (Task 2), epitaxial growth of V-defect and non-V-defect LEDs (Tasks 1, 3, 4, 5, 6), and advanced characterization methods (Task 7). All tasks have been completed. A description of each task completed follows from this section.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
NASA NTRS1991

Perceived control in rhesus monkeys (Macaca mulatta) - Enhanced video-task performance

This investigation was designed to determine whether perceived control effects found in humans extend to rhesus monkeys (Macaca mulatta) tested in a video-task format, using a computer-generated menu program, SELECT. Choosing one of the options in SELECT resulted in presentation of five trials of a corresponding task and subsequent return to the menu. In Experiments 1-3, the animals exhibited stable, meaningful response patterns in this task (i.e., they made choices). In Experiment 4, performance on tasks that were selected by the animals significantly exceeded performance on identical tasks when assigned by the experimenter under comparable conditions (e.g., time of day, order, variety). The reliable and significant advantage for performance on selected tasks, typically found in humans, suggests that rhesus monkeys were able to perceive the availability of choices.

Washburn, David A.↗
DOE OSTI2023

Naval Ship Counter Measure Capability (Final Report) [Slides]

Task 1: RUNQUIC.py was modified to add options 4 and 5, which run only the QUIC-PLUME and QUICPRESSURE codes without rerunning QUIC-URB. Task 2: We have verified that the RUNQUIC.py produces a WPC file to facilitate the interface with the CONTAM model. Task 3: RUNQUIC.py is now compatible with Python 3.8 and above. Task 4: The CMWD capability has been added QUIC-PLUME, which uses two new input files: QP_countermeasures.inp and QP_grounddep.inp. This first controls the efficiency of the CMWD system and when it is turned on and off and the second makes it possible to turn of tracking of surface deposition on the ocean surface. Task 5: This report was written for this task. Additionally, we are updating the QUIC Start Guide and RUNQUIC.py Guide, which will be made available once they have gone through the publication review process. Task 6: We performed a literature review on models for inertial deposition on the upwind faces of obstacles. We identified a model that was compatible with QUIC’s existing deposition model and implemented a first draft of this model in QUIC-PLUME. We have performed some preliminary qualitative testing, which shows the expected behavior. Further quantitative testing to fully validate the inertial deposition model.

97 MATHEMATICS AND COMPUTING↗
NASA NTRS1977

Task and work performance on Skylab missions 2, 3, and 4: Time and motion study: Experiment M151

Human task performance was evaluated under weightlessness conditions during long duration space flight in order to study the characteristics of the adaptation function. Results show that despite pronounced variability in training schedules and in initial reaction to the Skylab environment, in-flight task performance was relatively equivalent among Skylab crews, and behavioral performance continued to improve from beginning to end of all missions.

Kubis, J. F.↗
DOE OSTI2022

Magnetic Gears: The Key to Robust, Cost-Effective Hydropower Drivetrains

Based on previous demonstrated success at fabricating 5 and 10 kW scale magnetic gearbox (MGB) prototypes, Emrgy and its partners (the project team) proposed to design and construct a 100 kW scale MGB with a 30:1 gear ratio for the low-head hydro applications. The Statement of Project Objectives included tasks covering: 1) Market Applicability; 2) Technical Metrics; 3) Design (initial); 4) Electromagnetic (EM) Load and Structural Analysis; 5) Modal Analysis; 6) Sealing Design and 7) Final Design during Budget Period 1. Budget Period 2 included tasks covering: 1) Materials Procurement and Test Plan Development; 2) Assembly; and 3) Testing. The Market Applicability study (Task 1) led to a clear conclusion and recommendation toward “Low Head” technologies for maximum market share of both New Stream Reach development as well as powering Non-Powered Dams. The findings of this study also identified the opportunity for a larger scale magnetic gearbox-based drive train as a function of increased torque, as opposed to increased speed. The Technical Metrics Study (Task 2) concluded a horizontal orientation was preferred, examined potential loss mechanisms, concluded that a Halbach Array magnetic design was preferred, established a 30:1 gear ratio as optimal, and established a power rating of 100 kW as optimal. The subsequent initial and final detailed design process included electro-magnetic (EM) load and structural analysis (Task 4), a Modal analysis (for vibration) (Task 5), and a sealing design (Task 6) to assure water impermeability. The final design package (Task 7) included 729 individual parts, 117 unique part numbers, and 15 assemblies. In order to facilitate procurement, the full bill of materials was broken down into several sub-components: 1) custom magnetic parts; 2) custom machined parts; 3) custom casted parts; and 4) commercial off the shelf (COTS) parts. The casted parts were fabricated by Oak Ridge National Laboratory (ORNL) via a Cooperative Research and Development Agreement (CRADA) with Emrgy and funded by the Advanced Manufacturing Office (AMO). The procurement effort (Task 8) ultimately covered three time periods based on challenges encountered in meeting the budgeted cost for the prototype. Following the first effort in the early stages of Budget Period 2 in 2017, a no-cost time extension was granted to seek alternative fabrication and procurement options. The project was re-booted in 2020 based on the new ORNL CRADA that would focus on five (5) of the more difficult and expensive parts using their advanced manufacturing expertise. Procurement efforts for the other custom machined parts resulted in quotations that still exceeded the budget by more than $\$$100k. This was, in part, also due to the concurrent COVID-19 pandemic that caused both supply chain disruptions and labor shortages. As the project continued, pricing and availability degraded further. In Q2 FY’22, it was decided to not proceed with the fabrication of the prototype (Task 9) based on budgetary limitations. Outcomes included a full and detailed design of a 100 kW magnetic gearbox and associated indented bill of materials (BOM) and CAD drawings, a full assembly instruction manual with an associated BOM for materials necessary to support assembly, the fabrication of the double Halbach magnetic array for the rotor/stator system, fabrication of five (5) sand-casted/machined parts (via CRADA with ORNL) and an initial draft of a comprehensive testing plan. The most significant non-outcome was the actual fabrication and testing of the prototype gearbox based on budget limitations. Lessons learned included the need for an Application / Design / Cost trade analysis to better elucidate the cost potential of the MGB in the projected volumes anticipated for future demand. This would better establish the efficacy of the original cost target ($\$$0.80/Watt) and/or the need for reconsideration of designs and applications. Likewise, additional consideration of the prototype nature of the gearbox – single use, short lifetime, etc. - either as a separate exercise or in place of the design process completed, to reduce the cost of the demonstration prototype device. Additionally, project continuity was cited as a significant risk based on the loss of the primary design engineering firm after Budget Period 1. A design analysis exercise was conducted at the conclusion of the project to identify potential areas for cost reduction. One concept considered was the removal of the inner ring of magnets (with associated changes in the outer ring magnets) to enable a horizontal collapse of the design. It was estimated this could reduce cost by 10-25% without impacting performance.

13 HYDRO ENERGY↗